Production of foodstuffs with a filling

ABSTRACT

A frozen foodstuff is made by first molding a foodstuff blank while frozen under pressure into a first foodstuff part that has a cavity intended to hold a filling. Then filling is loaded into the cavity of the first foodstuff part while frozen. Finally a second frozen foodstuff part is fitted to the first foodstuff part to close the cavity. The mating edges of the parts can be coated with water and/or egg white to stick together, and the two parts can then be breaded or otherwise coated.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the US national phase of PCT applicationPCT/EP2003/000640, filed 23 Jan. 2003, published 25 Sep. 2007 as WO2003/077682, and claiming the priority of German patent application10212456.6 itself filed 20 Mar. 2002 and German patent application10247283.1 itself filed 10 Oct. 2002, whose entire disclosures areherewith incorporated by reference.

FIELD OF THE INVENTION

The invention relates to a method of making a frozen filled foodstuff.

BACKGROUND OF THE INVENTION

A foodstuff is known that is a pocket whose interior holds a filling,e.g. Cordon Bleu. In addition a foodstuff is known that completelycontains a filling. Both types of foodstuff are expensive to produce andit is highly likely that the filling leaks out when the foodstuff iseventually heated.

OBJECT OF THE INVENTION

It is an object of the invention to provide a method of making a frozenfilling-containing foodstuff that permits automatic mass-production andalso ensures exact control over weight and shape. Another object of theinvention is to provide a filled foodstuff whose filling can be countedon not to leak out.

SUMMARY OF THE INVENTION

These objects are attained according to the invention in that afoodstuff blank is molded while frozen under pressure into a firstfoodstuff part that has a cavity intended to hold a filling, thenfilling is loaded into the cavity of the first foodstuff part whilefrozen, and finally a second frozen foodstuff part is fitted to thefirst foodstuff part to close the cavity.

Alternately according to the invention the first foodstuff blank is notmade with such a cavity, and the filling is loaded onto it while frozen.Then according to this alternate embodiment of the invention the secondfoodstuff part is fitted to the first foodstuff part over the filling.

With such a process it is possible to make the two foodstuff parts, inparticular the two portion halves, with an exact shape and weight. Thefilling is loaded into one or both of the halves or foodstuff partseasily and surely and after closing of the two foodstuff parts a solidattachment of these two parts is created. In this manner an automaticprocess works with minimal waste and the tightest weight and volumetolerances.

A particularly solid attachment of the two foodstuff parts or halves isachieved when edges at which the two foodstuff parts engage each otherare coated with a liquid that adheres the edges together. The liquid canbe or contain water and/or egg white.

In a further possible embodiment it is suggested that the secondfoodstuff part also has a cavity that forms a cavity with the cavity ofthe first foodstuff part.

It is furthermore advantageous when after attaching the two foodstuffparts together an outer surface of the two foodstuff parts is providedwith an outer layer, in particular breading. This outer layer can holdthe two foodstuff parts or portions together.

BRIEF DESCRIPTION OF THE DRAWING

Embodiments of the invention are shown in the drawing and are moreclosely described in the following. Therein:

FIGS. 1 a-1 d show two foodstuff parts each having a cavity;

FIGS. 2 a and 2 b show two foodstuff parts of which only one has acavity.

SPECIFIC DESCRIPTION

Deep-frozen foodstuff parts 2 and 3 (e.g. of fish or sawed-off pieces ofa deep-frozen fish block) are shaped under pressure in appropriatelyformed dies or molds. The starting temperature of the foodstuff portionsis preferably −5° C. to −20° C. The pressurized shaping process isdescribed in German patent 198 06 391.

Coating of the molds is done manually or automatically. The completeddeep-frozen portion, product, or foodstuff part is shaped such that twoor more can be fitted together to form a pocket 1.

One part 2 is previously filled with another foodstuff or otherfoodstuffs, preferably herb butter, cheese, ham, sausage, specialfilling, or combinations thereof. Then the one part 2 in which thefilling has been loaded and a second empty part 3 are fitted together.This process also works with more parts.

Before fitting together, an additive, preferably water, egg white, or asimilar foodstuff acting as a binder, is applied to edges of the parts 2and 3 in order to ensure that the assembly holds together during laterhandling (as e.g. powder-coating, breading, cooking). The shape of thecutout 5 or cavity depends on requirements. Preferably it is high enoughthat it minimizes separation of the outer layer during furthertreatment.

The two foodstuff parts 2 and 3 can have the same shape, each with acavity 5. Alternatively the second part 3 can have no cavity or only avery shallow cavity in order for it to serve as base or cover for thefirst part 2.

In addition the first part can be flat or have only a slight, that isflat, cavity and serve as base so that, after setting the filling on it,it is covered by the second part that has a larger cavity.

1. A method of making a frozen foodstuff that contains a filling, themethod comprising the steps of sequentially: molding a foodstuff blankwhile frozen under pressure into a first foodstuff part that has acavity intended to hold a filling; loading filling into the cavity ofthe first foodstuff part while frozen, and fitting a second frozenfoodstuff part to the first foodstuff part to close the cavity.
 2. Amethod of making a frozen foodstuff that contains a filling, the methodcomprising the steps of sequentially: molding a foodstuff blank whilefrozen under pressure into a first foodstuff part; loading filling ontothe first foodstuff part while frozen, and fitting a second frozenfoodstuff part having a cavity to the first foodstuff part over thefilling.
 3. The method according to claim 1, further comprising the stepof: coating edges at which the two foodstuff parts engage each otherwith a liquid that adheres the edges together.
 4. The method accordingto claim 3 wherein the liquid is or contains water and/or egg white. 5.The method according to claim 1 wherein the second part is also formedwith cavity that forms a common cavity with the cavity of the firstfoodstuff part.
 6. The method according to claim 1 wherein afterattaching the two foodstuff parts together an outer surface of the twofoodstuff parts is provided with an outer layer.
 7. The method accordingto claim 1 wherein the foodstuff blank is fish, beef, pork, or fowl. 8.A method of making a frozen foodstuff that contains a filling, themethod comprising the steps of: shaping a foodstuff while frozen into afirst foodstuff part formed with a cavity and into a second foodstuffpart fittable with the first part to close the cavity; loading fillingonto one of the parts while it is frozen; and fitting the other of theparts while frozen to the one part while frozen to close the cavity withthe filling between the frozen parts.
 9. The method defined in claim 8wherein the second part is also formed with a cavity and is generallysymmetrically identical to the first part.